Battery rack and system

ABSTRACT

A frame device for supporting objects such as batteries during seismic stress, comprising a pair of end frame members mounted in upstanding spaced apart relation by a plurality of vertically spaced elongated channel support members secured at opposite terminal ends to the vertical columns of the end frame members, shelves for supporting batteries spanning the channel support members and defining a plurality of compartments for the batteries, each end frame member being formed of a single sheet material shaped to define vertical columns and a web extending between the end columns, a pair of anchors, means for securing the end frames to the anchors, and means defining a plurality of openings in the web of each end frame generally aligned with the compartments formed by the shelves to provide horizontal ventilation of batteries mounted in the compartments.

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/294,144 filed May 30, 2001.

FIELD OF THE INVENTION

[0002] The present invention relates to a rack for supporting andstoring objects and more specifically to a battery rack system andapparatus having a plurality of compartments for supporting batteriesand other heavy objects designed to survive seismic forces during earthtremors and the like. The invention relates specifically to framesforming part of what is known as an uninterruptable power source.

BACKGROUND OF THE INVENTION

[0003] There is a need, particularly in the telecommunicationsindustries, for a back up power source to maintain operations when theprimary power source shuts down. These systems generally comprises aplurality of valve regulated lead acid batteries (VRLA) generally of atwo volt size which are typically connected in series in variousnumbers, for example 24, to provide or define a 48 volt system. Thesebatteries are typically constructed of polypropylene jars which is arelatively soft material similar to milk jugs and a cover mounting theleads connected to the jar by a seam. These jars generally require anexterior shell for protection as well as pressure control. It has beenfound that without compression, these batteries tend to bulge therebydiminishing capacity.

[0004] In accordance with a known prior art system, the batteries arestored or placed in multi-cavity modules or trays which are stacked, oneon top of the other and secured to one another to provide an array ofassembled trays and batteries totaling the requisite number for a givensystem such as 24 batteries for a 48 volt system.

[0005] An important criteria for systems of this type is that thesupport structures function to support the heavy loads and be reliableparticularly in times of crises. These prior systems have certaindisadvantages and draw backs. For example, batteries are installed inthe modules at the battery plant or factory. Typically, a three batterymodule may weigh about 800 lbs. These trays are therefore rather bulkyand difficult to handle at the installation site. Further, the modulepockets, in some instances, are oversized relative to the battery andrequire the use of shims to snugly position the batteries in the modulepockets. The batteries are typically placed in the modules before thefinal charge creating pressure between the battery and the module.Accordingly, when the batteries swell, if there is need for theinstaller to remove the batteries, the batteries are usually gripped bythe posts which can cause battery damage. Further, it has been foundthat the interconnected modules are not always as stable as they shouldbe and do not satisfy the criteria for supporting heavy loads in time ofseismic crises.

[0006] Summarizing the disadvantages of the presently known systems, ithas been that cell damage results by overstressing the post seals wheninstallers handle the batteries by the posts, especially duringextraction of cell and lifting thereof.

[0007] Other adverse affects of extraction of cells from the modules ortrays include exposure of the jars to the ambient environment andpotential puncture. Further, extraction can result in jar to cover seamdamage during reinsertion of the cell into the modular trays. Further,in some instances, the jars are shimmed in the trays to maintainpressure. These shims are inserted prior to jar bulging and once the jarbulges, it is difficult to extract the cell from the trays and even moredifficult to reinsert them. Often the shim is not reused resulting inlose of pressure and thus diminishing capacity.

SUMMARY OF THE INVENTION

[0008] The rack assembly and system of the present invention obviatessome of the disadvantages and drawbacks of the prior system discussedabove. To this end, the rack system of the present invention comprises aframe device for supporting objects such as batteries during seismicstress, comprising a pair of end frame members mounted in upstandingspaced apart relation by a plurality of vertically spaced elongatedchannel support members secured at opposite terminal ends to thevertical columns of the end frame members, shelves for supportingbatteries spanning the channel support members and defining a pluralityof compartments for the batteries, each end frame member being formed ofa single sheet material shaped to define vertical columns and a webextending between the end columns, a pair of anchors, means securing theend frames to the anchors, and means for defining a plurality ofopenings in the web of each end frame generally aligned with thecompartments formed by the shelves to provide horizontal ventilation ofbatteries mounted in the compartments.

[0009] With the foregoing in mind it is an object of the presentinvention to provide an improved battery rack system characterized bynovel features of construction and arrangement providing certainfunctional advantages over the prior art systems discussed above.

[0010] A further object of the invention is to provide a battery racksystems which essentially consists of only two main structuralcomponents and therefore is easy and quick to assemble and install.

[0011] Still a further object of the present invention is to provide arack system including two relatively rigid end frame members configuredto define relatively large ventilation ports for horizontal air flowwhich improves battery performance.

[0012] A still further object of the present invention is to provide arack assembly and system which includes a novel, relatively rigid endframe structure and anchors which are easily accessible for securing theassembly on a concrete floor or the like.

[0013] Still another object of the present invention is to provide arack assembly and system wherein no side or rear access is required forassembly of the rack and the batteries therein and accordingly the rackassembly and system can be used in extremely small spaces. For example,the space required almost as small is the rectangular footprint of therack assembly.

[0014] A still another object of the present invention is to provide abattery rack assembly and systems wherein the frame including a novelconfiguration of end frame members which are symmetrical and thereforecan be manufactured economically and installed easily and which arecharacterized by a series of ventilation slots and webs between theslots which confront a plurality of open compartments in the rack forthe batteries to thereby aid and guide the batteries into the rowsdefined in the compartments.

[0015] Still another object of the present invention is to provide anovel battery rack assembly and system which has great flexibility andonly one designed frame is needed for the entire 120-size system productline in a 8-high configuration.

[0016] Still a further object of the present invention is to provide anovel battery rack assembly and system wherein the shelves are dividedinto rows or zones for the batteries defined by a series of spaceddimples and openings spacing the rows of batteries at a predetermineddistance from one another to whereby the ventilation slots facilitatevertical air flow over the batteries and with again the result ofimproving battery performance.

[0017] Still another object of the present invention is to provide anovel jacket configuration for the batteries characterized by a uniquedesign allowing for handling the cells individually thereby facilitatehandling and wherein the open end configuration is such to protect thejoint between the cover and the jar from damage.

[0018] Still another object of the present invention is to provide ajacket configuration where the cell need not be extracted from thejacket or handled by its posts and thereby eliminating cell posts sealdamage and jar damage as well as diminished capacity due to loss ofpressure characteristic of prior art configuration.

[0019] A still further object of the present invention is to provide anovel jacket arrangement constructed of two identical pieces which areconfigured to be easily welded together to form a neat compact jacketfor the individual batteries which includes points for picking up andhandling the batteries and therefore eliminates cell damage.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] These and other objects of the present invention and variousfeatures and details of the construction and operation thereof arehereinafter more fully set forth with reference to the accompanyingdrawings, wherein:

[0021]FIG. 1A is an exploded perspective view of end frames of the rackand the anchor or base channel for supporting the rack system on asupport surface such as concrete flooring in a commercial facility;

[0022]FIG. 1B is an enlarged view showing tabs or tangs on the feet ofthe end frame members which engage in slots in the base channel forrigidly supporting the end frames in the anchors or base channels;

[0023]FIG. 2A is a perspective view of the battery rack assembly showingthe shelf support channels and the shelves for the batteries and jacketsassembled to the end frames;

[0024]FIG. 2B is an enlarged partially cutaway view showing the boltedjoint between a shelf support channel and the end frame;

[0025]FIG. 2C is an enlarged view of the portion circled in FIG. 2Amarked 2C showing the shelf projections defining the zones separatingthe jackets and vertical air flow channels; FIG. 2D is an enlarged viewof the portion circled in FIG. 2A and marked 2D showing zone divider andair flow channels;

[0026]FIG. 2E is a perspective view of a modified embodiment of batteryrack including additional horizontal air flow ports;

[0027]FIG. 3A is a perspective view of the two components forming thebattery jacket;

[0028]FIG. 3B is a perspective view of the halves of the jackets weldedtogether;;

[0029]FIG. 4A is a perspective view of the battery rack assembly showingthe jackets and batteries in place in the shelves;

[0030]FIG. 4B is an enlarged view of the circled portion of FIG. 4Dshowing the jacket ears for securing the jacket to the shelves;

[0031]FIGS. 5A and 5B are enlarged views showing air flow around thebatteries on the rack;

[0032]FIG. 6 is a fragmentary front view showing the dimples forseparating the adjacent rows of batteries and jackets, which are alsoshown in FIGS. 2C and 2D;

[0033]FIG. 7 is an enlarged view along lines 7-7 of FIG. 4A showing thebattery held in place in the jacket and the rack assembly before theretainer bars are in place;

[0034]FIG. 8A is a perspective view of the battery rack assembly withthe battery retaining bars assembled;

[0035]FIG. 8B is an enlarged view showing the bolted joints between alarge and small retainer and a shelf;

[0036]FIG. 9 is an enlarged sectional view showing taken on line 9-9 ofFIG. 8 showing the retainer bar and compression strips;

[0037]FIG. 10A is a perspective view of a retainer bar;

[0038]FIG. 10B is a perspective view of a large retainer bar;

[0039]FIG. 11A is a perspective view of the battery rack assembly and aprotective shield overlying the cover of the array of batteries housedin jackets; and

[0040]FIG. 11B is an enlarged view of the portion circled in FIG. 11Amarked 11B showing the shield mounted bracket.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] Referring now to the drawings and particularly to FIG. 2 thereof,there is shown a battery rack assembly and system including the uniquefeatures of the present invention which is generally designated by thenumeral 10. The battery rack assembly 10 essentially comprises a pair ofspaced apart end frames 12 and 14, a series of shelf support channels 16which connect the end frames 12 and 14 and shelves 18 spanning thesupport channels which are spaced apart vertically to define a series ofcompartments for storing batteries in jackets in a manner described inmore detail hereafter. The end frames 12 and 14 are rigidly supported inbase channels 20 which can be anchored to a support surface such as aconcrete floor in a commercial building.

[0042] Considering now the components of the battery rack assembly 10 inmore detail and with specific reference to the end frames 12 and 14,each end frame may be fabricated from a single sheet of sheet metalpunched and formed to the configuration shown in the drawings. Since theend frames 12 and 14 are of identical configuration, like parts thereofwill be designated with the same reference numeral. Each end frame asillustrated is of a configuration to define a pair of elongated,vertically extending columns 22 and 24 generally C-shaped connect by agenerally rectangular web 26 having, in the present instance, a seriesof generally rectangular openings 28 arranged in two rows R₁ and R₂which facilitates horizontal ventilation of the batteries mounted in therack assembly to thereby improve battery performance. The foot of eachcolumn 24 has a depending tang 30 formed therein adapted to engage in aslot 32 formed in the anchor 20. The anchor 20 as illustrated in FIGS.1A and 1B is an elongated channel-shaped member of U-shaped crosssection having a generally rectangular base 34 and a pair of upstandingside walls 36 which at their outer terminal ends are beveled as at 38.The base 34 of the anchor is reinforced by a pad 40 adjacent the anchormounting hole 42. The end frame members 12 and 14 are easy to assembleto the anchor 20 by simply inserting the tangs 30 into the slot 32 andwelding the parts in place as at 44. Note, the transverse width W of thecolumns 22 and 24 is essentially the same width as the spacing S betweenthe side walls 36 of the anchor 20 so that the feet of the verticalcolumns 22 and 24 snugly embrace the side wall 36 when the verticalframe is assembled to the anchor 20. This adds to the rigidity of therack. Note that the pads and anchor holes 42 project beyond the verticalframe and shelf support channels for easy access.

[0043] Since there are only two main structural components, the endframe members 12 and 14 provide ease of installation. The ventilationslots 28 produce good generally horizontal air flow for improvingbattery performance. (See FIGS. 5A and 5B showing air flow.) The webs 46between the ventilation slots guide the batteries into position for easeof installation of the batteries as explained in more details below. Theframe configuration and design provide symmetry so that are no left orright considerations providing ease of installation and manufacture.

[0044] There is shown in FIG. 2E a modification of the end frameswherein a series of vent openings 45 are provides in the webs to furtherenhance cooling air flow to improve batteries performance.

[0045] Bolt holes 48,50 are provided in the vertically extending endfaces 47 of columns 22 and 24 of the vertical frame members to attachthe shelf support channels 16 and battery shield brackets 96. Asillustrated, there are a series of vertically spaced bolt holes 48arranged in pairs for mounting the shelf support channels 16 and aseries of vertically oriented pairs of bolt holes 50 for supportingbrackets 96 for the battery shield 94. As illustrated in FIG. 2B, shelfsupport channels 16 are supported between the end frames 12 and 14 bybolts 54 at opposite terminal ends to provide a rigid support structurewhen all of the shelf support channels 16 are in place.

[0046] The shelves 18 for the battery rack assembly comprise a generallyrectangular support panel section 56 having a depending flange 58 alongthe front edge thereof which has a series of bolt holes 60. The panelsection 56 is divided into three zones Z₁, Z₂ and Z₃ by transverselyextending alternating rows of spaced slots 62 and a series of upwardlyprojecting dimples 64. The slots 62 provide a vertical flow path forfurther ventilation of the batteries to further enhance batteryperformance. The dimples space the rows of batteries and jackets toenhance any flow. The shelves 18 are fixed in place by pairs of bolts 65at each of the bolt hole locations which as illustrated in FIGS. 2C and2D, engage through the adjacent innermost bolt holes in the shelf andaligned bolt holes in the channel support member 16.

[0047] Consider now the battery jacket J which is best illustrated inFIGS. 3A and 3B. The jacket J comprise two parts, top and bottom halves70 and 72, each formed from a single piece of sheet material to theconfiguration shown. As illustrated, the two parts 70 and 72 areidentical and comprise generally rectangular top and bottom panels 74and 76. The top and bottom panels 74 and 76 have partial side and bottomwalls which mate in the final configuration to form a box-like structureshown in FIG. 3B. Note that the jacket halves 70, 72 are welded togetheras at 78. The parts are provided with complementary buttons 80 and roundlocating holes 82 and enlarged obround locating holes 83 to position thejacket parts properly when performing the final weldment. The open endof the jacket J has upwardly and downwardly projecting ears 84 and 86which project forwardly of the front edge of the jacket J and arestaggered relative to one another for a purpose to be described.

[0048] Consider now use of a battery rack assembly 10 of the presentinvention. Batteries B are inserted into the jackets J, which happens atthe battery manufacturing plant prior to charging and bulging.

[0049] The jackets J, including batteries B, are loaded into thecompartments defined by the shelves 18 and the shelf support channels 16as shown in FIG. 4. Note that in this position the ears 84 and 86 of theadjacent jackets J are in side-by-side array by reason of the staggeredconfiguration of the ears 84 and 86. The jackets J are secured to theshelves 18 and the shelf support channels 16 by means of bolts 65extending through the center hole 67 of the three-hole array in thejacket ears 84 and 86.

[0050] It is noted that when the battery B bottoms in the jacket J, theseam S at the juncture of the cover C and jar J is located forward ofthe front edge E of the jacket defining the opening therein to therebyprevent damage to the seam S during insertion. Further, it is noted thatthe ears 84 and 86 project forwardly to allow assembly of the flatbattery retainer bars 90 and 92. As shown in FIG. 6, jackets J areguided into the zones or rows Z₁, Z₂ and Z₃ defined by the dimples 64 sothat they are spaced apart and create air ventilating channels 62 forenhancing battery performance. It also aligns the bolt openings in theears 84 and 86 with the corresponding holes 60 in the front flange 58 ofthe shelf 18. The batteries B are then fixed in place in the rack bymeans of retainer bars 90 and 92. The retainer bar 90 has two bolt holeopenings (not shown) and an enlarged central opening 55 whichcircumscribes/overlies the bolt heads 65 securing the jacket J to therack 10 and is used on the lowermost and uppermost jacket to secure thebattery in place in the upper and lowermost rows. The battery retainerbar 92 is elongated and has two sets of three openings 100, 101 and 102for use in the intermediate rows in the manner shown in FIG. 8. Note,the retaining bars 90 seating or securing the batteries in the uppermostand lowermost rows, the openings are offset to one side so that thelower portion of the retaining overlaps the cover of the battery in themanner shown in FIG. 8A. The bars 90 and 92 are provided with elongatedstrips extending along top and bottom edges to provide a cushion effectwhen securing the retaining bars in place. The openings in the longerbars 92 are centrally located to the bar to provide the same overlapwith the cover in adjacent rows in the manner shown in FIG. 8B.

[0051] In some instances, a shield 94 overlying the front of the rack isused to further protect the batteries and to protect persons from thebatteries' exposed, live connectors. The shield 94 in the presentinstance comprises of two generally rectangular, clear plastic sectionswhich are supported over the front face of the rack by S-shaped brackets96 secured to the vertical columns 22, 24, 24a of the frame members 12and 14. The plastic sheets 94 are provided with key-hole slots 98 attheir corners for cooperative engagement with headed fastening elements99 carried by the outer end of the brackets 96.

[0052] Even though particular embodiments of the present invention havebeen illustrated and described herein, it is not intended to limit theinvention and changes and modifications may be made therein within thescope of the following claims.

What is claimed is:
 1. A frame device for supporting objects such as batteries during seismic stress, comprising: a pair of end frame members mounted in upstanding spaced apart relation by a plurality of vertically spaced elongated channel support members secured at opposite terminal ends to the vertical columns of the end frame members; shelves for supporting batteries spanning the channel support members and defining a plurality of compartments for the batteries; each end frame member being formed of a single sheet material shaped to define vertical columns and a web extending between the end columns; a pair of anchors; means for securing the end frames to the anchors; and means defining a plurality of openings in the web of each end frame generally aligned with the compartments formed by the shelves to provide ventilation of batteries mounted in the compartments.
 2. A rack assembly as claimed in claim 1 wherein the shelves are divided into a plurality of zones and each zones is separated in a manner spacing the adjacent rows of batteries and including slots as part of the zone defining means which allow for vertical ventilation of the batteries.
 3. A battery rack assembly as claimed in claim 1 wherein the vertical columns are provided with depending tangs or tabs adjacent their lower ends which engage in slots in the anchors for securing the rack assembly to a floor surface.
 4. A frame device as claimed in claim 1 wherein each of the vertical columns has a depending tab which engages in a slotted opening in the anchor and wherein the anchor is of U-shaped cross-section and wherein the columns snugly engage seat between the side walls of the anchor to provide a relatively rigid assembled structure.
 5. A frame device as claimed in claim 1 wherein each of the shelves is divided into zones by a series of slots and projecting dimples to position the rows of batteries in space relation and allow vertical ventilation of the batteries when they are mounted in the compartments.
 6. A frame device as claimed in claim 1 wherein the batteries are snugly mounted in jackets which are open at one end and have transversely projecting ears for securing the jackets in the compartments, said ears spaced outwardly from the edge defining the opening in the jacket, said jackets being of a depth slightly less than the length of the battery so that the seam between the cover and the jar is positioned exteriorly of the jacket.
 7. A frame device as claimed in claim 1 wherein the ears on opposing side edges of the jacket are staggered so that when they are assembled in the compartments the ears adjacent the jackets in adjacent compartments are positioned next to one another.
 8. A frame device as claimed in claim 1, including retainer bars spanning the ears of the jacket for securing them in place.
 9. A frame device as claimed in claim 1, including a protective cover overlying the front face of all the batteries in the various compartments.
 10. A frame device as claimed in claim 9, wherein protective cover has a plurality of openings permitting insertion of a probe for testing each of the batteries.
 11. A battery rack assembly for supporting objects such as batteries during seismic stress, comprising: a pair of end frames connect spaced apart in relation by a series of channel support members, each of said frame members being made of a single piece of sheet material and shaped to define a pair of spaced elongated columns of confronting C-shaped cross-section and a web connecting the columns having a series of openings providing cross ventilation for the compartments defined by the spaced channel support members; said end frame members mounted in anchors which are adapted to be secured to a support surface such as a floor and a plurality of shelves spanning the channel shelf supports to define a plurality of compartments for storing the batteries. 